High toughness metallic glass-based composites for additive manufacturing

ABSTRACT

Methods and alloy systems for non-Be BMG matrix composite materials that can be used to additively manufacturing parts with superior mechanical properties, especially high toughness and strength, are provided. Alloys are directed to BMGMC materials comprising a high strength BMG matrix reinforced with properly scaled, soft, crystalline metal dendrite inclusions dispersed throughout the matrix in a sufficient concentration to resist fracture.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/514,653, filed Jun. 2, 2017, the disclosure of which is incorporated herein by reference.

STATEMENT OF FEDERAL FUNDING

The invention described herein was made in the performance of work under a NASA contract NNN12AA01C, and is subject to the provisions of Public Law 96-517 (35 USC 202) in which the Contractor has elected to retain title.

FIELD OF THE INVENTION

The present invention generally relates to bulk metallic glass matrix composite materials with enhanced strength and toughness, methods of their additive manufacture, and parts manufactured therefrom and thereby.

BACKGROUND OF THE INVENTION

Bulk metallic glasses (BMGs), also known as amorphous or glassy metals, are alloys which can be quenched into a vitreous state at a relatively large casting thickness (generally over 1 mm). In turn, BMG matrix composites (BMGMCs) are two-phase materials, comprising a crystalline/dendrite phase dispersed within a high strength metallic glass matrix, wherein the crystalline phase is, typically, grown in situ via chemical segregation during the alloy's cooling from melt in casting.

Metal additive manufacturing, also commonly known as metal 3D printing, is an emerging manufacturing technology, which is being rapidly integrated into commercial applications, such as fabrication of nozzles in aircraft and rocket engines. Typically, a 3D printing process comprises sequential deposition of a multitude of thin layers of a material to assemble a desired bulk (or net-shape) part or structure. The most common forms of metal additive manufacturing are based on either powder bed systems or powder feed systems. In 3D printing based on powder bed systems, a laser or electron beam melts a thin layer of metal powder and continuously applies it to construct the part, which becomes buried in the powder. The most common forms of powder bed systems are direct metal laser sintering (DMLS) or selective laser melting (SLM). In contrast, in printing systems based on powder feed systems, metal powder is blown into a laser or electron beam and deposited as a metal pool. In addition, there exist 3D printing systems in which a metal is deposited directly from a building head in the absence of a powder bed. Such bed-less technologies are termed directed energy deposition (DED), of which the most common form is laser engineered net shaping (LENS). Other common forms of metal additive manufacturing are deposition, thermal spray additive manufacturing, laser foil welding, and ultrasonic additive manufacturing. Recently, it has been shown that bulk metallic glass parts can also be fabricated by additive manufacturing instead of casting.

SUMMARY OF THE INVENTION

Embodiments according to the disclosures generally relate to bulk metallic glass matrix composite materials with enhanced strength and toughness, methods of their additive manufacture, and parts manufactured therefrom and thereby.

Many embodiments according to the disclosure are directed to methods for forming a bulk metallic glass matrix composite utilizing powder-based additive manufacturing including:

-   -   mixing a powder of a bulk metallic glass composition with a         powder of at least one additional metallic composition wherein         the at least one additional metallic composition forms a         reinforcing crystalline ductile phase configured to inhibit         crack propagation in a bulk metallic glass matrix formed from         the bulk metallic glass composition, and wherein the volume         fraction of the at least one metallic crystalline phase is from         between 15-95% by volume of the bulk metallic glass matrix         composite;     -   melting the mixed powder of the bulk metallic glass composition         and the at least one additional metallic composition using an         additive manufacturing heating source such that the at least one         additional metallic composition is partially melted such that a         native oxide layer disposed within the bulk metallic glass         matrix composition is dissolved; and     -   solidifying the melt formed from the mixed powders in a layer by         layer printing process to form the bulk metallic glass matrix         composite having at least one property selected from the group         of a porosity of equal to or less than 2% by volume, an overall         strength of at least 50% of the strength of the bulk metallic         glass composition when formed into a bulk part, a fracture         toughness that is at least 5% larger than bulk metallic glass         composition, a tension ductility that is at least 1% larger than         the bulk metallic glass composition, and a notch toughness         larger than 40 MPa m^(1/2) when measured in a part formed from a         bulk metallic glass composition with a notch radius of 100         micrometers.

In many other embodiments, the layer by layer solidification process is selected from the group of powder bed fusion, selective laser melting, direct metal laser sintering, direct energy deposition, electron beam fabrication, thermal spray additive manufacturing, cold spray additive manufacturing and binder jetting.

In still many other embodiments, the powder of the bulk metallic glass composition powder and the powder of the at least one additional metallic composition are mixed before solidification.

In yet many other embodiments, the bulk metallic glass composition powder particle size is within 20% of the particle size of the at least one additional metallic composition powder.

In still yet many other embodiments, the solidified bulk metallic glass matrix composite has a strength of greater than 1 GPa.

In still yet many other embodiments, the solidified bulk metallic glass matrix composite has a ductility in tension of greater than 4%.

In still yet many other embodiments, the fracture toughness of the solidified bulk metallic glass matrix composite exceeds 80 MPa m^(1/2).

In still yet many other embodiments, the at least one additional metallic composition does not substantially alter the glass forming ability of the bulk metallic glass composition.

In still yet many other embodiments, the method further includes machining or finishing the solidified bulk metallic glass matrix composite to smooth the surface thereof.

In still yet many other embodiments, the bulk metallic glass matrix composite is applied to a crystalline metal surface.

In still yet many other embodiments, the hardness of the at least one additional metallic composition is at least 5% lower than the hardness of the bulk metallic glass composition.

In still yet many other embodiments, the shear modulus of the at least one additional metallic composition is lower than the shear modulus of the bulk metallic glass composition.

In still yet many other embodiments, the stiffness of the at least one additional metallic composition is lower than the stiffness of the bulk metallic glass composition.

In still yet many other embodiments, the at least one additional metallic composition is a crystalline metal that exhibits greater than 5% ductility in tension as a monolithic part.

In still yet many other embodiments, the at least one additional metallic composition is comprised of the same primary metal element as the bulk metallic glass composition.

In still yet many other embodiments, the bulk metallic glass composition is selected such that its most abundant metal is selected from the group of Ti, Zr, Hf, Fe, Co, Ni, Pd, Pt, Cu, Ag, Au, and Al.

In still yet many other embodiments, the bulk metallic glass composition comprises Zr—Cu—Al.

In still yet many other embodiments, the bulk metallic glass composition is a Ti-based metallic glass with a density of less than 5.5 g/cm³.

In still yet many other embodiments, the bulk metallic glass composition is Zr-based and the at least one additional metallic composition is Ti or Zr based alloyed with one or more of V, Nb, Ta, Mo or Fe.

In still yet many other embodiments, the bulk metallic glass matrix composite may comprise one of the following: is based on Ti and has a density of less than 6 g/cm³, is based on Ti and the at least one additional metallic composition is based on Ti, is based on Fe and the at least one additional metallic composition is based on Fe.

In still yet many other embodiments, the bulk metallic glass composition is Fe—Ni—B—X, where X is one or more additional components, and the at least one additional metallic composition is based in Fe.

In still yet many other embodiments, the bulk metallic glass composition is based on Al, and the at least one additional metallic composition is based on Al.

In still yet many other embodiments, the bulk metallic glass matrix composite is printed into a three-dimensional object selected from the group of watches, jewelry, electronic cases, structural components, gears, and kinetic rounds.

In still yet many other embodiments, the volume fraction of the at least one additional metallic composition is varied throughout the solidified bulk metallic glass matrix composite.

In still yet many other embodiments, the at least one additional metallic composition comprises a refractory metal phase selected from the group of W, Mo, Hf, or Ta.

In still yet many other embodiments, the solidified bulk metallic glass matrix composite is formed as a net shape part.

In still yet many other embodiments, a dendrite phase forms in the bulk metallic glass matrix during melting and solidification from a component dissolved from the at least one additional metallic composition having low solubility in the bulk metallic glass composition.

In still yet many other embodiments, the solidified bulk metallic glass matrix composite comprises three phases: the bulk metallic glass matrix, the reinforcing crystalline ductile phase, and a dendritic phase distributed throughout the bulk metallic glass matrix.

In still yet many other embodiments, the compositions of the bulk metallic glass composition and the at least one additional metallic composition are selected such that when the at least one additional metallic composition is partially dissolved into the bulk metallic glass composition, the bulk metallic glass composition has improved glass forming ability.

In still yet many other embodiments, the at least one additional metallic composition contributes sufficient metal components to the bulk metallic glass composition during melting such that the bulk metallic glass matrix has improved glass forming ability when compared to the glass forming ability of the bulk metallic glass composition prior to melting.

Additional embodiments and features are set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the disclosed subject matter. A further understanding of the nature and advantages of the present disclosure may be realized by reference to the remaining portions of the specification and the drawings, which forms a part of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying data and figures, wherein:

FIG. 1 provides a schematic of a temperature time diagram of the critical cooling rate for forming a metallic glass according to prior art.

FIG. 2A compares mechanical properties of BMG alloys and conventional crystalline alloys.

FIG. 2B provides an image illustrating a brittle fracture of a BMG alloy according to the prior art.

FIG. 3A provides a table showing fracture toughness and yield strength values for various materials according to the prior art.

FIG. 3B illustrates a fracture of a conventional BMG accordance to the prior art.

FIG. 4A provides a schematic diagram of composite materials in accordance with embodiments.

FIG. 4B provides images of fracture propagation in a composite metallic glass material (left), and a monolithic metallic glass material (right).

FIGS. 5A to 5F provide data showing properties of BMGMCs and monolithic BMGs in accordance with the prior art.

FIGS. 6A to 6C provide data showing properties of BMGMCs in accordance with the prior art.

FIG. 7 provides data demonstrating the effect of beta stabilizers on the formation of composite materials in accordance with the prior art.

FIG. 8 provides a heat flow data graph of Zr and Ti-BMGMCs in accordance with the prior art.

FIG. 9 provides images of cast parts of Zr and Ti-BMGMCs in accordance with the prior art.

FIG. 10A provides data showing properties of toughness vs elastic mismatch.

FIG. 10B provides micrograph images of composites comprising soft (top) and hard (bottom) inclusion in accordance with embodiments.

FIG. 11 provides a process for forming BMGMCs by a semi-slid process in accordance with the prior art.

FIG. 12 provides a schematic showing the cooling rate dependence on dendrite size in accordance with the prior art.

FIG. 13 provides a flow chart of a method of forming a BMGMC in accordance with embodiments.

FIGS. 14A to 14C provide tables of materials for use in BMGMCs in accordance with embodiments.

FIGS. 15A and 15B provide schematics of methods of forming BMGMCs in accordance with embodiments.

DETAILED DISCLOSURE

The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to precise forms disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention.

Turning to the data and figures, embodiments of methods and alloy systems for non-Be BMG matrix composite materials that can be used to additively manufacturing parts with superior mechanical properties, especially high toughness and strength, are provided. Alloys of embodiments are directed to BMGMC materials comprising a high strength BMG matrix reinforced with properly scaled, soft, crystalline metal inclusions dispersed throughout the matrix in a sufficient concentration to resist fracture.

Amorphous metals, also known as metallic glasses, are relatively new materials possessing a unique combination of advantageous properties that makes them attractive candidates for a wide variety of applications, including gears, cutting tools, bearings, electronic casings, jewelry, spacecraft components, and other useful parts and mechanisms. (See, e.g., U.S. patent application Ser. Nos. 13/928,109; 14/177,608; 14/259,608; 14/491,618; 15/062,989; and Ser. No. 15/918,831, the disclosures of which are incorporated herein by reference.) For example, these materials typically exhibit excellent corrosion and wear resistance, high strength and high hardness, yet, simultaneously, substantial elasticity. Moreover, manufacturing of parts from metallic glass alloys is, in principle, compatible with such straightforward processes as injection molding or similar casting processes. However, forming of amorphous metals into useful parts remains challenging, especially in the production of parts with dimensions exceeding 1 mm, due to the limitations associated with the need for extremely high cooling rates (i.e. critical cooling rate R_(c)) necessary for quenching of the metallic glass melts into vitreous state, wherein the glassy melt must be solidified faster than competing crystallization can occur, as depicted in FIG. 1.

In short, bulkier (thicker) parts, which require longer time to fully cool and solidify, are more difficult to manufacture without loss of advantageous properties afforded by the glassy phase. In addition, as can also be seen from FIG. 1, bulk metallic glasses are extremely sensitive to post-production heat treatments. For example, prolonged exposure of a metallic glass alloy to temperatures around its corresponding glass transition temperature will ultimately result in crystallization and loss of all advantageous properties.

One parameter used to characterize the glass forming ability (GFA) of a metallic glass alloy is the “critical rod diameter” (d_(c)), wherein the better glass formers are able to yield thicker (i.e. having larger critical rod diameters), fully amorphous parts at a given cooling rate. Another way of framing the glass forming ability of an amorphous metal is by the minimum cooling rate R_(c) required for a material to form an amorphous phase, wherein this “critical cooling rate” determines the types of manufacturing processes available. For example, very poor glass forming materials can have critical cooling rates as high as 10⁶° C./s. Another parameter that relates to the glass forming of a material is fragility. Fragility characterizes how rapidly the dynamics of a material slow down as it is cooled toward the glass transition: materials with a higher fragility have a relatively narrow glass transition temperature range, while those with low fragility have a relatively broad glass transition temperature range. The most common definition of fragility is the “kinetic fragility index” m, which characterizes the slope of the viscosity (or relaxation time) of a material with temperature as it approaches the glass transition temperature from above. Physically, fragility may be related to the presence of dynamical heterogeneity in glasses, as well as to the breakdown of the usual Stokes-Einstein relationship between viscosity and diffusion.

When a material is placed under stress and has reached the limit of its strength, it usually has the option of either deformation or fracture. A number of parameters may be used to describe the strength of metallic glasses when placed under stress, including: toughness, brittleness, fragility, etc. Toughness is the ability of a material to absorb energy and plastically deform without fracturing. One definition of material toughness is the amount of energy per unit volume that a material can absorb before rupturing. It is also defined as a material's resistance to fracture when stressed. Toughness generally requires a balance of strength and ductility. In general terms, a material is considered brittle if, when subjected to stress, it breaks without significant plastic deformation. Brittle materials, even those of high strength, absorb relatively little energy prior to fracture. FIGS. 2A and 2B illustrate that bulk metallic glasses typically have no ductility and are very brittle in tension, especially as compared to conventional crystalline aluminum alloys (FIG. 2A), breaking easily under stress as a result (FIG. 2B). Nevertheless, as illustrated in FIGS. 3A and 3B, BMGs are also high strength materials with large plastic zone size, capable of resisting crack formation. In other words, conventional BMGs are strong materials that are not prone to crack formation, however, once a crack does from within a BMG solid, it propagates effortlessly, due to the material's brittleness and results in a catastrophic failure.

One approach to improving ductility and, therefore, toughness of BMG alloys is illustrated in FIG. 4A and comprises incorporation of soft, crack arresting inclusions into the hard but brittle BMG matrix, wherein the inclusions are size-scaled to match the plastic zone size of the glass matrix (FIGS. 3A and 3B). To this end, bulk metallic glass matrix composite (BMGMC) materials, wherein a strong bulk metallic glass matrix incorporates a dispersed soft, crystalline metal dendrite phase have been reported to possess unprecedented mechanical properties, especially as compared to monolithic BMG materials or even high performance conventional crystalline alloys like steel. For example, FIG. 4B demonstrates that dendrites of a BMGMC alloy DH1 (FIG. 4B, left) efficiently blunt a crack tip and arrest the crack growth, in contrast to the fatal failure of a monolithic BMG alloy Vit1 (FIG. 4B, right) to withstand cracking and fracture.

Hofmann et. al. have demonstrated that the mechanical properties of BMGMCs based on Zr—Ti—Be—X and Ti—Zr—Be—X alloy families (wherein X represents one or more β-stabilizing elements and/or other glass forming ability enhancing elements) can be enhanced beyond the expectations afforded by the simple rule of mixtures (Hofmann, et. al., PNAS, 105(51) 20136-20140 (2008) and Hofmann et. al., Nature (2007), the disclosures of which are incorporated herein by reference). Specifically, as illustrated in FIGS. 5A through 5F, Hofmann et. al. have shown that rational modifications to the BMGMC alloy's chemical composition, volume fraction size of the dendrite phase, modulus of the composite phases, and toughness of the metallic glass matrix—can all afford greatly enhanced mechanical properties. More specifically, Hofmann et. al. have developed a family of Ti—Zr—V—Cu—Be BMGMCs (the DV-DVAI family) with different dendrite volume fractions, wherein DV4, DVAI1 and DVAI2 all had >60% BCC dendrites (FIGS. 5A and 5C). The resulting alloys were not only amenable to cooling into billets larger than 1 cm thick (FIG. 5B), but also possessed a host of enhanced mechanical properties, as compared to traditional crystalline alloys, such as Ti alloys (FIGS. 5C through 5E) or monolithic BMGs (FIG. 5F). The excellent BMGMC properties reported by Hofmann et. al. included: yield strengths greater than 1.5 GPa, ductility greater than 5% in tension, fracture toughness values greater than 100 MPa m^(1/2) (FIGS. 6A & 6B), fatigue endurance limits greater than 20% of the yield strength (FIG. 6C), and excessive ductility in bending.

Nevertheless, despite the many demonstrated advantages of Zr—Ti—Be—X and Ti—Zr—Be—X-based BMGMCs, their use in engineering applications has not become widespread due to the problems associated with alloy formulation and manufacturing. Specifically, the primary disadvantage of these alloys is that they usually contain beryllium, which is considered toxic, even in small amounts as a minor alloy component. However, Be has been considered necessary for ensuring good glass forming ability in the BMG matrix (ensuring d_(c)>1 mm), with no suitable alternatives available despite years of research. Moreover, in instances when BMGMC is formed in situ via phase separation of insoluble alloy components, Be is often necessary to promote and enhance the dendrite phase separation, as it has very low solubility in the BCC (β) allotropic form of Group 4 metals (i.e. Zr, Ti, Hf), which, in turn, are the most common BMGMC formers (as summarized in FIG. 7). In addition, removing Be dramatically increases the melting temperature of the alloy, making it difficult to cast. For example, FIG. 8 illustrates that substituting Be in alloy DV1 (as summarized in FIG. 5C) for Al to form Ti₅₂Zr₁₈V₁₂Cu₁₅Al₃, while maintaining approximately the same Ti—Zr—V presence and the same dendrite volume fraction, increases the solidus temperature by 210 degrees, making the new Al-containing alloy barely castable and no longer amorphous. Furthermore, dendrite-containing BMGMCs have very high viscosity (much higher than monolithic BMGs), making their casting problematic, especially in view of also higher melting temperatures. As such, mold casting of BMGMCs often leads to mold damage from overheating (which is necessary to lower the alloy viscosity) and poor quality, dull in their appearance, cast parts. For example, FIG. 9 demonstrates the challenges associated with casting BMGMC alloys that have a dendrite volume fraction of more than 50%, including the increase in cast part defects or incomplete casts. Accordingly, the manufacturing of parts from BMGMC alloys, wherein the parts are complex, Be-free, and possess desirable properties, such as high strength and toughness, remains unattainable with conventional die-casting or injection molding.

Embodiments of BMGMC Materials

Embodiments are generally directed to methods and alloy systems for non-Be BMG matrix composite materials that can be used to additively manufacture parts with superior mechanical properties, especially high toughness and strength. As discussed above, to date, the development of BMGMCs has primarily been restricted by the requirement that they are amenable to casting, and, therefore, efforts have focused on the alloys with good glass forming ability of the BMG matrix, facile phase separation of the dendrite phase, low melting temperature, and relatively low dendrite concentration. However, as also discussed above, the alloys obtained under such restrictions tend to be brittle, as their microstructures do not arrest the development of fatal cracks.

Accordingly, alloys of embodiments are directed to BMGMC materials comprising a high strength BMG matrix reinforced with properly scaled, soft, crystalline metal dendrite inclusions dispersed throughout the matrix in a sufficient concentration to resist fracture. In many embodiments, the BMG matrix and crystalline metal dendrite inclusions are selected such that there is the highest possible elastic (i.e. shear modulus) mismatch between the phases. Specifically, as shown in FIG. 10A using the first Dundurs' parameter it is possible to predict how the relative toughness of a composite will be impacted by the elastic mismatch between its phases. More specifically, higher relative toughness can be obtained where a soft dendrite phase is included in a harder matrix, and where the elastic mismatch parameter between the materials is maximized. (See, e.g., Launey, M. E., et al., PNAS, 106(13), pp. 4986-4991 (2009), the disclosure of which is incorporated herein by reference.) The difference in the way hard and soft inclusions develop boundary layers phases is shown in FIG. 10B.

Specifically, soft inclusions in a hard continuous matrix better prevents the propagation of fractures through the composite material by concentrating stress in the glass phase such that deformation initially occurs by necking (10A, top), as opposed to hard inclusions in which stress is concentrated in the crystalline phase and shear bands form along the amorphous phase by shear fracturing (10B, bottom). Accordingly, in many embodiments the elastic mismatch (Dundrus parameter α) between the matrix and the inclusions is less than 0, and in other embodiments less than −0.5. Other embodiments are directed to composite materials where the matrix phase is at least 5% harder than the crystalline phase, and is provided in sufficient concentration capable of resisting fracture.

As shown in the schematic provided in FIG. 4A, the composites according to embodiments generally comprise at least two phases: a soft crystalline phase (shown by the circles and voids) dispersed throughout a continuous high strength matrix phase. It has been shown that a certain minimum particle amount/volume fraction is required in the solidified alloy in order to achieve the desired crack suppression effect and, as a result, to minimize brittleness and acquire satisfactory ductility. Accordingly, in many embodiments the concentration of inclusions in the matrix is at least ^(˜)15% by volume or above, in other embodiments from ^(˜)15% by volume up to 95% by volume in order to ensure sufficient fracture toughness in the BMGMCs.

Turning to the compositions of the BMGMCs in accordance with embodiments, the combination of the BMG matrix material and the crystalline phase material may follow a number of possible compositional rules. In many embodiments, addition of the crystalline phase does not substantially alter the glass forming ability of the bulk metallic glass matrix composition. In many other embodiments, the hardness of the at least one additional metallic composition is at least 5% lower than the hardness of the bulk metallic glass matrix composition. In still other embodiments, the shear modulus of the at least one additional metallic composition is lower than the shear modulus of the bulk metallic glass matrix composition. In yet other embodiments the stiffness of the at least one additional metallic composition is lower than the stiffness of the bulk metallic glass matrix composition. In various embodiments, the at least one additional metallic composition is a crystalline metal that exhibits greater than 5% ductility in tension as a monolithic part. In various other embodiments the at least one additional metallic composition is comprised of the same primary metal element as the bulk metallic glass matrix composition.

Turning to the actual compositions of the composite materials, in many embodiments the bulk metallic glass matrix composition is selected such that its most abundant metal is selected from the group of Ti, Zr, Hf, Fe, Co, Ni, Pd, Pt, Cu, Ag, Au, and Al. In some embodiments the bulk metallic glass matrix composition is ZrCuAl. In other embodiments, the bulk metallic glass matrix composition is a Ti-based metallic glass with a density of less than 5.5 g/cm³. Ins till other embodiments, the bulk metallic glass matrix composition is Zr-based and the at least one additional metallic composition forming the crystalline phase is Ti or Zr based alloyed with one or more of V, Nb, Ta, Mo or Fe. In many embodiments the crystalline phase may be formed of a refractory metal phase selected from the group pf W, Mo, Hf, or Ta. In various embodiments, the bulk metallic glass matrix composite may comprise one of the following: be based on Ti and have a density of less than 6 g/cm³, be based on Ti and where the at least one additional metallic composition forming the crystalline phase is based on Ti, is based on Fe and the at least one additional metallic composition forming the crystalline phase is based on Fe. In some embodiments the bulk metallic glass matrix composition is Fe—Ni—B—X, and the at least one additional metallic composition forming the crystalline phase is based on Fe. In other embodiments, the bulk metallic glass matrix composition is based on Al, and the at least one additional metallic composition forming the crystalline phase is based on Al.

Embodiments of Methods for Forming BMGMC Materials

As discussed above, the formation of successful BMGMC materials requires the ability to systematically control the concentration and size of particles in the metal matrix. Conventionally, the crystalline dendrite phase of the composite is formed in situ during casting (due to the segregation of specially added insoluble alloy components upon cooling and solidification of the cast melt). As summarized in FIG. 11, the best composite materials have been achieved by creating equilibrium composites where dendrites are in thermal equilibrium with the glass forming BMG liquid and their size is controlled through semi-solid processing, as shown in FIG. 12. These properties have been nearly impossible to replicate in other, non-Be BMGMCs, due to crystallization of the matrix and due to the wrong selection of the particles. Likewise, significant ductility in tension and fracture toughness has only been achieved in Be-containing BMGMCs. Moreover, the literature suggests that the excellent properties of BMGMCs can only be obtained using semi-solid (or isothermal) holds above the solidus temperature to coarsen the dendrites.

In many embodiments, the BMGMC microstructures that lead to the advantageous alloy properties in the current disclosure are “synthesized” either in situ or ex situ using non-Be containing BMG powder for the matrix material, crystalline metal powder for the soft inclusions phase, and metal additive manufacturing. Accordingly, in many embodiments, the fabrication process comprises the steps tabulated in FIG. 13. As shown, in many embodiments, first, a BMG powder suitable for use with a powder utilizing metal additive manufacturing processes is selected. In many embodiments, the powder utilizing metal additive manufacturing processes of interest may include one of: powder bed fusion, direct metal laser sintering, direct energy deposition, laser engineered net shaping, thermal spray additive manufacturing, or another powder utilizing process. Such methods are in direct contrast to conventional semi-solid processes as with additive manufacturing there is no way to do semi-solid processing due to the rapid heating and cooling involved in the process.

Furthermore, in many embodiments, the BMG powder for 3D manufacturing of tough parts according to the methods of the application is selected such that if it were to be 3D printed as a monolithic part, the resulting BMG would be able to exhibit a notch toughness of at least 40 MPa m^(1/2). In some such embodiments, the BMG powder with such characteristics may help ensure that the critical shear band spacing in the BMGMC material 3D printed according to the methods of the application is large enough to interact with the particles prior to printing. In many embodiments, the BMG powder alloy composition is selected from, for example, the Tables provided in FIGS. 14A through 14C. In many embodiments, the selected BMG powder may then be used to form the high strength matrix of the BMGMC alloys of the application.

In many embodiments, the BMG powder selected according to the criteria described above is next blended with one or more soft crystalline powders. In many embodiments, the added powder forms the reinforcing phase of the BMGMC alloys of the application. In many embodiments the added powder (or powders) is selected from the list: crystalline metal powder, amorphous metal powder, any combination thereof. In many embodiments, the powder particle size of the added powder is within 20% of the powder particle size of the matrix's BMG powder. In many embodiments, in addition to matching the particle size of the blended powders, the density of the blended alloys is also closely matched (e.g., within 20%). In many embodiments, such powder particle size or particle size and density agreements between the blended powders ensures the prevention of sedimentation during the mixing or printing of the feedstock. In addition, in many embodiments, the absolute powder particle size is between 20-200 micron in diameter. In many such embodiments, the powder particle size of between 20-200 micron in diameter ensures that the particles are large enough to match the length scale of the BMGMC deformation and, therefore, provide the maximum composite reinforcement benefit to the BMG matrix (as explained by Hofmann et. al. in Nature 2007, the disclosures of which are incorporated herein by reference). Finally, in many embodiments, the volume fraction of the added reinforcement powder is between 15% and 95% of the alloy. In many such embodiments, the presence of more than 15% of the reinforcement additives by volume ensures sufficient distance between the dendrites to effectively stop cracks. Concurrently, maintaining the volume fraction of the reinforcement additives below 95% ensures sufficient BMG matrix contribution to the alloy's strength. This is, of course, only possible if the BMG matrix exhibits a lower melting temperature than the reinforcing particles such that a matrix forms during additive manufacturing so as to prevent percolation of the softer phase through the part.

In accordance with embodiments of the invention the bulk metallic glass matrix composites made in accordance with the embodiments described herein may have a number of physical properties that are improved over conventional composites, including, a porosity of equal to or less than 2% by volume, an overall strength of at least 50% of the strength of the bulk metallic glass composition when formed into a bulk part, a fracture toughness that is at least 5% larger than bulk metallic glass composition, a tension ductility that is at least 1% larger than the bulk metallic glass composition, a notch toughness larger than 40 MPa m^(1/2) in some cases larger than 80 MPa m^(1/2) and in some cases larger than 100 MPa m^(1/2) when measured in a part formed from a bulk metallic glass composition with a notch radius of 100 micrometers, a strength of greater than 1 GPa and in some instances greater than 1.2 GPa, a ductility in tension of greater than 4%.

Embodiments of Methods for Additive Manufacturing of BMGMC Parts

As discussed above, embodiments of BMGMC materials incorporate high volume fractions of soft inclusions, however, as found by prior art studies an increased inclusion volume fraction also makes the alloys more viscous and significantly raises their melting temperature, especially upon exclusion of Be additives, making them more difficult to cast. Recently, metal additive manufacturing (AM) technology (also known as 3D printing) has made rapid advances in the fabrication of net-shaped parts from novel metal alloys. Typically, metal AM has been used to fabricate components from conventional crystalline metal alloys, such as titanium, steel, casting aluminum alloys, and Inconel. However, the rapid cooling rates inherent to many AM technologies have also allowed for the fabrication of metastable alloys, such as bulk metallic glasses (BMGs) and nanocrystalline metals. Specifically, cooling rates in excess of 10³ K s⁻¹ for each deposited layer have allowed thick, net-shaped components to be printed from alloys that have microstructures (or lack thereof) that cannot be cast or otherwise manufactured in bulk form.

As discussed above, AM processes have typically not been used in the manufacture of objects from BMGMCs, because the best properties have been achieved by creating equilibrium composites where dendrites are in thermal equilibrium with the glass forming BMG liquid and their size is controlled through semi-solid processing. With additive manufacturing, there is no way to do semi-solid processing due to the rapid heating and cooling process. In many embodiments, additive manufacturing processes are used to form both BMGMC materials and objects therefrom. Schematics of such embodiments are provided in FIGS. 15A and 15B. As shown, in many embodiments, first, a BMG powder suitable for use with a powder utilizing metal additive manufacturing processes is selected. In many embodiments, the powder utilizing metal additive manufacturing processes of interest may include one of: powder bed fusion, direct metal laser sintering, direct energy deposition, laser engineered net shaping, thermal spray additive manufacturing, or another powder utilizing process. In many embodiments, the BMG powder selected according to the criteria described above is next blended with one or more soft crystalline powders. In many embodiments, the added powder forms the reinforcing (dendrite) phase of the BMGMC alloys of the application. In many embodiments the added powder (or powders) is selected from the list: crystalline metal powder, amorphous metal powder, any combination thereof. (This process is summarized in FIG. 15A.) Once the BMGMC material is formed it can be deposited layer by layer using an additive manufacturing process, such as, for example, powder bed fusion, direct metal laser sintering, direct energy deposition, laser engineered net shaping, thermal spray additive manufacturing, or another powder utilizing process. (This process is summarized in FIG. 15B.)

It will be understood that parameters for the fabrication of BMGMC parts from the powdered feedstock selected according to the methods of the application are adjusted according to the methods described herein to ensure the proper alloy microstructure and, accordingly, enhanced toughness and ductility. In many such embodiments, the heating source of the additive manufacturing set-up is adjusted to accommodate the proper heating/melting of the heat sensitive BMG powders. As such, in some embodiments, the additive manufacturing process of the application takes advantage of the lower melting temperature of the BMGs as compared to the melting temperature of the crystalline powder inclusions; while in other embodiments the process uses a more rapid sweep of the heating means to take advantage of the differential coupling with the laser heating source. Furthermore, in many embodiments, the heating source of the additive manufacturing process may be adjusted to ensure that, upon melting followed by solidification, the BMG powder forms a solid composite matrix with less than 2% porosity. Since BMGs cannot be heat treated to remove porosity post-production (due to the heat sensitivity of the amorphous phase), it is critically important for the overall toughness of the 3D printed BMGMCs of the application to maintain their full density during the fabrication process. In many embodiments, the thickness of each deposited BMGMC layer is <250 micron, wherein each layer is cooled faster than 100 K/s, and in some embodiments faster than 1,000 K/s (FIG. 15B). The presence of the reinforcing phase may actually assist in the formation of higher density parts through printing by providing an interface for the molten melt to wet against, preventing cavitation. The particles may also assist in the cooling rate of the molten BMG matrix upon solidification by accumulating heat during cooling away from the matrix, allowing it more easily to form a glass. This is due to the higher thermal conductivity and heat capacity of the crystalline phase as opposed to the glassy phase.

Furthermore, in many embodiments, the additive manufacturing methods of the application ensure that the inclusion crystalline particles are homogenously distributed throughout the BMG matrix of the composite. In many embodiments, the particles of the additive reinforcement powders do not fully dissolve into the BMG matrix during the printing process, but retain at least 90% of their pre-print volume. Since BMG alloys typically have a much lower melting temperature than crystalline alloys, the BMG may be melted without significantly melting the reinforcement powder. However, in many embodiments based on laser-based 3D printing systems, multiple passes of the laser over one layer of the part may be used to consolidate the BMG matrix, while also partially dissolving the reinforcement powder until the optimal properties are achieved. In other embodiments, different heating methods may be used to preferentially melt the BMG powder, with only minor/partial melting of the reinforcement dendrite powders. Accordingly, the BMGMC alloys additively manufactured ex situ from a feedstock of blended powders, according to the embodiments of the application, achieve the high toughness and ductility of the in situ formed BMGMCs, wherein the BMG matrix is responsible for the alloy's strength, while the reinforcing crystalline inclusions (i.e. the second phase) provide the toughening mechanism by inhibiting any crack propagation originating from the matrix. As such, in many embodiments, it is equally important for the BMGMCs of the application to have a sufficiently tough BMG matrix to prevent the crack formation in the regions between the particle inclusions, and a sufficient concentration of the inclusions to block the crack propagation if the matrix cracks do occur, as described above.

The additive manufacturing methods of the application ensure that there is a strong interface between the dendrite inclusion and matrix phases in the BMGMC alloys of the application. More specifically, in many embodiments, precautions are taken to ensure that the toughness of the interfacial zone between each of the inclusions and the BMG matrix is sufficiently high to prevent any occurring crack from traversing the edge of the particle phase without deforming it (as described in Ritchie, Hofmann, Applied Physics Letters 2009, the disclosures of which are incorporated herein by reference). For example, in many embodiments, precautions are taken to remove or at least partially reduce the thickness of the brittle oxide layer (that typically forms on the BMG surfaces) from the BMG powder particles during the additive manufacturing process. To this end, in many embodiments, the BMG powder particles are partially melted during the additive manufacturing process to dissolve the surface passivating oxide layer and, thus, ensure the sufficiently tough matrix-dendrite interface and overall enhanced material toughness. In contrast, failure to at least partially dissolve the BMG surface oxide will most likely result in loss of the overall material toughness because the cracks originating in the matrix will be able to escape the dampening effect of the dendrite inclusions via the brittle oxide matrix-dendrite interface pathways. In addition, in many embodiments, the original powder selection process ensures the chemical compatibility between the reinforcement and matrix phases, such that a small amount of surface oxide and dendrite components dissolved in the matrix during manufacturing do not compromise the toughness or glass formation of the solidified BMG matrix.

In other embodiments, the particle is designed so that when partially dissolved in the BMG matrix during processing, the extra metal added to the matrix does not detrimentally effect its glass forming ability, and may actually enhance it. This could be accomplished by creating a BMG powder slightly depleted in elements that would optimize its glass formation and then have those elements returned by partially dissolving the reinforcing particles to a known extent. In a further embodiment, partially dissolving the reinforcing particles may create small dendrites in the matrix upon solidification, which may provide an additional reinforcing phase. The final printed composite could then be comprised of a glass matrix, large reinforcing particles, and small dendrites that have phase separated from the glass during solidification.

Using the methods according to embodiments bulk metallic glass matrix composite parts may be printed. In such embodiments, the volume fraction of the at least one additional metallic composition may be varied throughout the solidified bulk metallic glass matrix composite. The final part may be formed net-shape or may be machined or finished to smooth the surface thereof. Although the layer-by-layer deposition may be applied to other metallic glasses, in some embodiments they be applied to a crystalline metal surface. The methods may be used to form any suitable object including, for example, watches, jewelry, electronic cases, structural components, gears, and kinetic rounds.

Exemplary Embodiments

The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the present invention, and are not intended to limit the scope of what the inventors regard as their invention nor are they intended to represent that the experiments below are all or the only experiments performed. Efforts have been made to ensure accuracy with respect to numbers used (e.g. amounts, temperature, etc.) but some experimental errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, molecular weight is weight average molecular weight, temperature is in degrees Celsius, and pressure is at or near atmospheric.

Example 1. Improving Mechanical Properties of Zr-Based BMG Alloys

An example of additive manufacturing (via SLM) with monolithic BMG-affording Zr_(52.5)Ti₅Cu_(17.9)Ni_(14.6)Al₁₀, was reported by Li et. al. in Materials and Design 112 (2016) 217-226, the disclosure of which are incorporated herein by reference. The data from the accompanying compression tests reported by Li show that the resulting additively manufactured BMG parts are brittle. However, the Zi-based alloy employed by Li is a good glass former not containing Be, with a composition similar to the ones provided in the table of FIG. 14A, and, therefore, represents an alloy suitable for the additive manufacturing methods of the application. Accordingly, in many embodiments, the plasticity, and, therefore, toughness, of the parts fabricated from Zr_(52.5)Ti₅Cu_(17.9)Ni_(14.6)Al₁₀ can be greatly improved with in situ or ex situ addition of a reinforcing dendrite phase during 3D printing, according to the methods of the application.

Example 2. Improving Mechanical Properties of Fe-Based BMG Alloys

Similarly to Example 1, inexpensive monolithic BMG parts have been previously additively manufactured (also via selective laser melting) from Fe-based BMG alloys, such as Fe₇₄Mo₄P₁₀C_(7.5)B_(2.5)Si₂, as reported, for example, in Simon Pauly, et al., Materials Today, Vol. 16, Numbers 1/2, (2013), p. 37-41; and Hyo Yun Jung, et al., Materials & Design, Vol. 86 (2015), p. 703-708, the disclosures of which are incorporated herein by reference, these parts proved to be brittle, as expected from monolithic BMGs. However, in many embodiments, the fracture toughness and ductility of Fe₇₄Mo₄P₁₀C_(7.5)B_(2.5)Si₂ or similar alloys can be improved with in situ or ex situ addition of a reinforcing dendrite phase during 3D printing, according to the methods of the application.

DOCTRINE OF EQUIVALENTS

This description of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications. This description will enable others skilled in the art to best utilize and practice the invention in various embodiments and with various modifications as are suited to a particular use. The scope of the invention is defined by the following claims. 

The invention claimed is:
 1. A method for forming a metallic composite part utilizing powder-based additive manufacturing comprising: providing a powder of a bulk metallic glass composition for forming a bulk metallic glass matrix, wherein the bulk metallic glass composition is characterized by a glass forming ability and is beryllium-free, and a powder of at least one additional metallic composition for forming a ductile crystalline phase within the bulk metallic glass matrix; mixing the powder of the bulk metallic glass composition with the powder of the at least one additional metallic composition to create a powder mix, wherein a volume fraction of the powder of the at least one additional metallic composition is between 15% and 95% of the powder mix; melting a layer comprising the powder mix using an additive manufacturing heating source such that at least the powder of the bulk metallic glass composition is at least partially melted such as to dissolve a surface passivating oxide layer inherent to the powder of the bulk metallic glass composition; and solidifying the layer to form a bulk metallic glass matrix composite comprising the ductile crystalline phase comprising the at least one additional metallic composition dispersed within the bulk metallic glass matrix comprising the bulk metallic glass composition, wherein a volume fraction of the ductile crystalline phase comprises between 15 and 95% of the bulk metallic glass matrix composite; the ductile crystalline phase inhibits crack propagation within the bulk metallic glass matrix and reinforces the bulk metallic glass matrix composite; and the bulk metallic glass composite is characterized by at least one property selected from the group consisting of: a porosity of equal to or less than 2% by volume, an overall strength of at least 50% of a strength of the bulk metallic glass composition when formed into a monolithic part, a fracture toughness that is at least 5% larger than a fracture toughness of the bulk metallic glass composition, a tension ductility that is at least 1% larger than a tension ductility of the bulk metallic glass composition, and a notch toughness larger than 40 MPa m^(1/2) when measured in a part with a notch radius of 100 micrometers; repeating melting and solidifying steps in an additive manufacturing process to deposit a plurality of layers comprising the bulk metallic glass matrix composite atop one another to form a bulk metallic glass matrix composite part.
 2. The method of claim 1, wherein the additive manufacturing process is a process selected from the group consisting of: powder bed fusion, selective laser melting, direct metal laser sintering, direct energy deposition, electron beam fabrication, thermal spray additive manufacturing.
 3. The method of claim 1, wherein the powder of the bulk metallic glass composition is characterized by a first particle size and the powder of the at least one additional metallic composition is characterized by a second particle size, and wherein the first particle size is within 20% of the second particle size.
 4. The method of claim 1, wherein the bulk metallic glass matrix composite is characterized by the overall strength of greater than 1 GPa.
 5. The method of claim 1, wherein the tension ductility is greater than 4%.
 6. The method of claim 1, wherein the fracture toughness exceeds 80 MPa m^(1/2).
 7. The method of claim 1, where the at least one additional metallic composition does not substantially alter the glass forming ability of the bulk metallic glass composition.
 8. The method of claim 1, further comprising machining or finishing the bulk metallic glass matrix composite part to smooth the surface thereof.
 9. The method of claim 1, where the bulk metallic glass matrix composite part is applied to a crystalline metal surface.
 10. The method of claim 1, wherein the at least one additional metallic composition is characterized by a hardness at least 5% lower than a hardness of the bulk metallic glass composition.
 11. The method of claim 1, wherein the at least one additional metallic composition is characterized by a shear modulus lower than a shear modulus of the bulk metallic glass composition.
 12. The method of claim 1, wherein the at least one additional metallic composition is characterized by a stiffness lower than a stiffness of the bulk metallic glass composition.
 13. The method of claim 1, where the at least one additional metallic composition is a crystalline metal that exhibits greater than 5% ductility in tension as a monolithic part.
 14. The method of claim 1, wherein the at least one additional metallic composition and the bulk metallic glass composition comprise the same metal element as their most abundant element.
 15. The method of claim 1, wherein the bulk metallic glass composition is selected such that its most abundant metal is an element selected from the group consisting of: Ti, Zr, Hf, Fe, Co, Ni, Pd, Pt, Cu, Ag, Au, and Al.
 16. The method of claim 1, where the bulk metallic glass composition comprises Zr—Cu—Al.
 17. The method of claim 1, where the bulk metallic glass composition is a Ti-based metallic glass with a density of less than 5.5 g/cm³.
 18. The method of claim 1, wherein the bulk metallic glass composition is Zr-based and the at least one additional metallic composition is based on Ti or Zr alloyed with one or more elements selected from the group consisting of: V, Nb, Ta, Mo, and Fe.
 19. The method of claim 1, wherein the bulk metallic glass matrix composite is based on Ti and has a density of less than 6 g/cm³.
 20. The method of claim 1, wherein the bulk metallic glass composition comprises Fe—Ni—B, and the at least one additional metallic composition is based on Fe.
 21. The method of claim 1, wherein the bulk metallic glass composition and the at least one additional metallic composition are both based on an element selected from the group consisting of: Al, Fe, Ti.
 22. The method of claim 1, wherein the bulk metallic glass matrix composite part is an item selected from the group consisting of: watch, jewelry, electronic case, structural component, gear, and kinetic round.
 23. The method of claim 1, wherein the volume fraction of the ductile crystalline phase is varied throughout the bulk metallic glass matrix composite part.
 24. The method of claim 1, wherein the at least one additional metallic composition comprises a refractory metal phase selected from the group consisting of: W, Mo, Hf, or Ta.
 25. The method of claim 1, wherein the at least one additional metallic composition comprises a component having a low solubility in the bulk metallic glass composition, and wherein a dendrite phase forms in the bulk metallic glass matrix from the component being dissolved in the bulk metallic glass composition.
 26. The method of claim 25, wherein the bulk metallic glass matrix composite comprises three phases: a glass phase comprising the bulk metallic glass matrix, a crystalline phase comprising the ductile crystalline phase, and a dendrite phase comprising the component.
 27. The method of claim 1, wherein the bulk metallic glass composition and the at least one additional metallic composition are selected such that when the at least one additional metallic composition is at least partially dissolved into the bulk metallic glass composition, the glass forming ability of the bulk metallic glass composition improves.
 28. The method of claim 27 wherein the at least one additional metallic composition contributes components to the bulk metallic glass composition when dissolved to improve a glass forming ability of the bulk metallic glass matrix as compared to the glass forming ability of the bulk metallic glass composition. 